Planning and Execution of a Mass Concrete Placement

utilizing Insulation Regimen

Ufuk Dilek Ph.D. , P.E.
Concrete Subject Matter Expert
The Shaw Group
128 S. Tryon Street Suite 600
Charlotte, NC 28202
Tel: 1 (704) 343 46 26
E-Mail: [email protected]

Abstract
This paper summarizes the planning and execution stages of a critical mass concrete
placement performed during summer months. The subject structure was a critical
component of a large heavy industrial facility, consisting of large load bearing elevated
flexural members. The planning and execution of this critical mass placement consisted
of multiple tasks.
A laboratory study was performed for the purpose of making improvements to the
mixture proportions existing and currently in use, admixture dosages and investigating
placement temperature options. Adiabatic and semi adiabatic temperature rise was also
measured during the laboratory study along with set times. Final proportions and
admixture dosages were selected as a result of the laboratory phase. Primary outcome
was increase in fly ash percentage from the existing mix design to control heat of
hydration.
Based on the findings of the measured adiabatic temperature rise, a thermal control plan
was developed adapting the new approach to structural mass concrete placements. A
thermal protection/insulation regimen was developed using the mix parameters,
expected ambient temperatures following placement, member dimensions and
formwork/blanket insulation properties. The pre-placement modifications to the
mixture proportions and the delivery temperature requirements protected the concrete
against high internal temperatures and potential of Delayed Ettringite Formation (DEF),
while the insulation regimen protected the concrete against rapid cooling and
occurrence of thermal gradients between core and perimeter.
As part of the thermal control plan analysis, target placement temperatures were
recommended to control maximum temperatures to prevent occurrence of DEF, in light
of the heat rise of the modified mix. The placement temperature was accomplished by
starting the placement at night and the use of ice to draw the temperature down. Upon
completion of finishing, a curing compound was applied in lieu of water curing and the
placement was insulated.
The thermal control plan simulation predicted a gradual reduction in the temperature of
the placement, within limits of maximum internal temperatures and temperature
gradients. The actual placement was monitored for core and perimeter temperatures
using maturity probes. Monitoring enabled the team to react to abrupt changes in
temperature if any was to occur. The placement was completed successfully with
internal temperatures and gradients controlled within the desired ranges.
Keywords: mass concrete, adiabatic heat rise, thermal control plan, fly ash, thermal
cracking, heat or hydration

Introduction
This paper summarizes the planning and execution stages of a critical mass concrete
placement performed during summer months. The subject structure was a critical
component of a large heavy industrial facility, consisting of large load bearing elevated
flexural members, with minimum dimensions exceeding 7 ft [Figure 1]. The planning
and execution of this critical mass placement consisted of multiple tasks.

Figure 1 Overview of beams showing reinforcement congestion.

Planning and execution consist of the following stages:
1.
2.
3.
4.

Laboratory Study
Development of the Thermal Control Plan
Post-Placement Thermal Monitoring
Curing, Insulation and Protection against Temperature Changes

Laboratory Study
Subject mass concrete placement was scheduled to occur during summer months. The
existing concrete mixtures used on site were not utilized to date in a mass concrete
placement of this significance and under the summer ambient conditions. Therefore the
concrete mixture planned for use was reviewed in light of the placement specifics. A
laboratory study was performed to revise the concrete mixture to achieve desirable
performance objectives in the mass concrete placement under summer ambient
conditions.
Existing concrete mixture utilized class F ASTM C 618 (ASTM, 2008) fly ash at a 25%
replacement rate. Existing concrete mixtures typically used type A (lignin based) water
reducers meeting ASTM C 494 (ASTM, 2010). Lignin based water reducer also offered

set control benefits in addition to reduction of water. In addition, as warranted by

reinforcement congestion and consolidation challenges at the bottom of sizeable
reinforced concrete members a type F superplasticizer meeting ASTM C 494 (ASTM,
2010) was utilized to achieve a maximum slump of 8 inches. Compressive strength of
the concrete mixture (fc) was 4000 psi (27 Mpa) and specification required water-tocementitious ratio maximum was 0.45.
Variables Used during Laboratory Study
During the laboratory study, concrete mixtures with 25% and 35% fly ash replacement
rates were tested. In addition, the dosages of type A and type F water reducers were
modified in coordination to yield the same slump value, while increasing the relative
dosage of type A in the mixture and achieving an increase in the time of set.
Laboratory study also included concrete mixtures batched at varying temperatures.
Temperature of water and aggregates was modified to achieve resulting batch
temperatures ranging between 21 and 32 C (70 and 90 F) enabling evaluation of the
changes with temperature, in time of set and retention or loss of slump. A total of 10
concrete trial batches were performed.
The laboratory study aimed to identify the combination of factors such as concrete
placement temperature, admixture dosages, fly ash replacement rate prior to the
placement. In addition to time of set and slump loss, adiabatic and semi-adiabatic heat
rise of concrete mixtures was measured and the information gathered was used in the indepth planning of the mass concrete placement.
Figure 2 shows semi adiabatic heat rise measurements performed using Adiacal TM
apparatus by WR Grace. This device mainly contains multiple insulated cylinder
housing compartments for 4 x 8 in (10 cm x 20 cm) cylindirical specimens. The
housing compartments are equipped with themocouples feeding temperature data to the
data acquisition hardware and associated software. The measurements are not fully
adiabatic as is evident from the eventual decline in temperature. However, a time of set
determination made based on the shape of the curve provides an estimate of the time of
set, which can be compared or indexed to times of set determined per ASTM C 403
(ASTM 2008). For this study, the subject device was not used for an absolute
determination of time of set but for comparisons between various trial batches with
different attributes. In general, the comparisons between mixtures were made on the
basis of
maximum magnitude of temperature achieved,
the occurence time of this peak temperature, and
occurence of the flat portions of the curve with respect to admixture
dosage and retardation effects.
These attributes can be observed in Figure 2.

Figure 2 Thermal measurements using Adiacal.

Selected Mixture Proportions
Based on the findings of the study, the mixture proportions nominated for placement
were determined. These proportions are provided in Table 1 below. It was decided to
utilize an increase fly ash replacement rate of %35. As a consequence of the increased
fly ash usage, an (fc) of 4000 psi (27 Mpa) determined at 56 days was utilized in lieu
of the typical 28 day mixture design cycle. This increase in length of the design cycle
aimed to reduce the earlier heat of hydration which would be more pronounced if the
design cycle was kept at 28 days and a more agressive water-to-cementitious ratio was
used for the 28 day design.
Based on the behavior of mixtures and Adiacal data, a likely upper limit for placement
temperature was initially considered to be 80 F (27 C). Under standard operating
measures, the supplying concrete plant was producing concrete just under 90 F (32 C)
during the heat of the summer season. If this temperature limit of 80 F was to be
confirmed by the thermal control plan development, it would likely be necessary to use
manually loaded ice as a replacement to batch water and that the placement be
performed at nighttime.

Table 1 Selected Mixture Proportions.

Code
Strength

1435
4000 psi
lb/CY
412 lb
222 lb
1112 lb
1852 lb
285 lb
0.45
3.5 - 6.5
5 to 8 in

Cement Type I/II

Fly Ash
Fine Aggregate
Coarse Agg. (67)
Water
W/(C+F)
Air (%)
Slump w/HRWR

1435
27.6 Mpa
kg/m3
245
132
660
1100
169
0.45
3.5 - 6.5
12.5-20 cm

Subsequently, full adiabatic thermal measurements were performed on the final selected
proportion. Figure 3 shows this measurement on the mixture containing 35% ash and a
mix containing 25% ash for comparison, demonstrating the difference made with
increasing the fly ash. An increase of 10% in fly ash results in a reduction of 3 C (5
F).

Figure 3 Adiabatic measurements, 35 % fly ash ( left), 25% fly ash (right).

DEVELOPMENT OF THE THERMAL CONTROL PLAN

ACI 207 Mass Concrete Committee Report
In general, ACI 207 (ACI, 2005) committee report (Guide to Mass Concrete)
concentrates on unreinforced, large mass structures, such as dams with typically lower
strength requirements than reinforced structural concrete. The guidelines provided for
mixture attributes (low heat, use of pozzolan, reduction of cement content etc) are
appropriate. The recommended curing method is curing by water therefore aiming
rapid removal of heat from the mass concrete structure.

ACI 207 committee is currently working on a committee report entitled Guide to

Reinforced Concrete Structures that is geared towards reinforced mass concrete
structures that are not sizeable as dams and possibly of a higher strength class. This
reports approach is generally inline with the mass concrete practice in ACI 301-10
(ACI, 2010). The fundamental difference in the new approach is in the curing regime.
The new approach states water curing cools the concrete surface rapidly and
concentrates on prevention of thermal cracking that can occur due to thermal differences
between a cooler perimeter and a hot core.
In general the new approach promotes use of pozzolans, reduction of cement content for
control of heat of hydration, as well as controlling delivered concrete temperature by
way of shading or evaporative cooling of aggregates and use of ice or liquid nitrogen, if
warranted. The internal temperature of concrete is not recommended to exceed 71 C
(160 F) to eliminate the potential for the occurence of a phenomenon called delayed
ettringite formation (DEF).
In addition to the internal temperature limit, the second criteria is a temperature
differential between core and perimeter. This value is typically 19 C (35 F) although
can be revised based on aggregate mineralogy and coefficient of thermal expansion
(Bamforth) The recommended method of curing to prevent rapid drop of temperatures
involves insulation of the concrete surface and use of moisture retentive barriers or
curing compounds as a method of curing. The recommended method of curing with
insulation is counter intuitive for mass concrete placements that generate heat, however,
it is intended to control temperature drop of the surface, unlike the water curing method.
Development of the Thermal Control Plan
A commercially available system, Quadrel TM was used in development of the thermal
control plan recommendations (CES, 2010). This system incorporates the adiabatic
thermal measurement for the concrete mixture, concrete delivery temperature, member
dimensions, expected ambient temperature ranges during and following placement, and
insulating values of forms and blankets as input. The associated software aims to
develop a simulation of thermal profiles for a given set of parameters in an effort to
develop thermal control plan specifics such as duration of protection, extent of
insulation etc. The simulation allows sensitivity analysis by modifying input parameters
and observing the effects on the outcome, in an effort to identify a combination of
parameters that are achievable and provide the desired outcome.
The thermal control plan aimed to protect the concrete against thermal cracking by an
insulation regimen, over the prescribed protection period, under the given ambient
conditions, while satisfying the two objectives of core temperature and temperature
differential.
Upon completion of the thermal control plan the upper limit for placement temperature
was determined to be 80 F (27 C). Under standard operating measures, the supplying
concrete plant was producing concrete just under 90 F (32 C) during the heat of the
summer season. It was therefore decided to use manually loaded ice as a replacement to
batch water and that the placement be performed at nighttime.

In addition to the 27 C (80 F) placement temperature limit, an ambient daily

temperature range of 16 38 C (60 -100 F), typical wind speeds, and insulating values
of forms and blankets (R value 5 F-ft2-h/Btu) were input into the simulation. Upon
completion of the simulation, as shown in Table 2, under daily temperature range of 16
38 C (60 -100 F), concrete placed at 27 C (80 F) was predicted to reach a
maximum internal temperature of 67 C (152 F). (CES, 2010)
The insulation was required to be kept on the structure for a minimum of 7 days to
maintain temperature gradients within the established differential limit. This period was
concident with the specification required curing period which could occur concurrently
with insulated protection.
Table 2. Maximum internal temperatures and required insulation period for 16 38
C (60 -100 F) daily temperature range.

Figure 4 shows results of one of the simulation runs. Based on the results of the
analysis, insulation can be removed and the protection can be terminated after 7 days,
when the temperature of the surface and core have reduced relatively and somewhat
converged. The analysis suggests upon removal of the insulation, the temperature of the
surface would start to demonstrate more pronounced fluctuations in response to the
ambient temperature fluctuations, however this would not constitute a violation of the
temperature differential limit since the core values have dropped as well. If the concrete
was not insulated during the early age period, the exterior temperatures would rapidly
drop and approach 16 38 C (60 -100 F) range. The rapid reduction of the external
temperatures would constitute a large temperature gradient relative to the hot core at the
time and impose thermal strains on the concrete that is of relatively young age and of
lower strength.

Figure 4 Simulation run for 16 38 C (60 -100 F) ambient temperature range and
7 day protection period and 80 F placement temperature
Temperature Monitoring Locations
In order to monitor temperatures following placement, the two largest beams were
equipped with temperature sensors, typically used for maturity metering per ASTM
1074 (ASTM, 2010). Sensors were placed at perimeter and core locations (Figure 5),
(CES, 2010)..

Figure 5 Monitoring Locations

.
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EXECUTION OF CONCRETE PLACEMENT

Concrete Placement
The thermal control plan and the associated analysis required a placement temperature
no higher than 27 C (80 F) and that the placement be performed at night with use of
ice to achieve this placement temperature. Figure 6 shows the placement during night
time.

Figure 6 Nighttime Placement.

Due to the hot summer ambient conditions, the aggregate stockpiles were sprayed
during the day to benefit from evaporative cooling. Up to 75 % of the batch water was
replaced with ice during batching. Concrete temperatures were monitored both during
the record testing as well as in-situ by the field crew using manual infrared
thermometers. Figure 7 shows concrete in-situ temperature after running through the
pump, measured at 25 C (77 F).

Figure 7 Concrete temperature in the form during nighttime placement.

After the concrete placement was complete, a curing compound was applied and the
concrete finished surfaces as well as the vertical surfaces of the side forms were
insulated for a period of 7 days per the requirements of the thermal control plan.

Monitoring
Sensors were placed at the pre-determined locations, fixed to the reinforcing steel cage,
or supported on dedicated supports and activated prior to the placement. Sensor cables
were extended to a central location for monitoring and a communication box fed the
data to the dedicated computer at the job-site office over the cell phone network.

Figure 8 Maturity sensors and centralized monitoring junction box.

The measured data was monitored and reviewed periodically. This real-time monitoring
provided site crew the ability to react and modify the extent of insulation if temperatures
were observed to exceed the prescribed limits.
The temperature data indicated that maximum temperatures did not exceed 71 C (160
F) which is the limit for prevention of occurence of DEF. (Figure 9). The measured
data was in general agreement with the simulated temperature values. It was noted that
the measured perimeter temperatures exhibited fluctuations following ambient
temperatures, as forecasted by the simulation. The measured data also indicated that the
temperature differential between core and perimeter did not exceed (25 F) and was
generally controlled within the prescribed limit.

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Figure 9 Measured temperatures.

Results
The measures developed as a result of the thermal control plan and the associated
analysis enabled a controlled reduction of the concrete temperature. If insulation regime
was not adapted, temperature differentials between core and exterior could have
exceeded the prescribed limit. In general maximum internal temperature and the
temperature differential was kept within the prescribed limits. Temperature levels were
monitored during the protection period and following the protection period using
maturity sensors. Real-time monitoring provided the capability to react and modify the
extent of insulation if temperatures were observed to exceed the prescribed limits. The
placement and protection period was completed succesfully with no apparent thermal
cracking and without exceeding the limits on temperature magnitude and differential.
The planning leading up to the placement contained several stages. During the
laboratory phase, the heat of hydration was reduced based on the modifications made to
the concrete mixture. Subsequently, measures such as evaporative cooling of the
aggregates, use of ice, nightime placement enabled reduction of the placement
temperature. These measures were effective in preventing the concrete from reaching
detrimental temperature levels which could lead to formation of DEF. The thermal
simulation utilizing, adiabatic heat rise, member sizes, insulation properties, ambient
conditions as input provided estimates of the expected core temperatures and
temperature gradients. While the core temperatures were kept under control with
mixture modifications and delivery temperature reduction, the temperature gradients
were controlled with the insulation regimen following placement.

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References
American Concrete Institute (2005), ACI 207.1R-05
Michigan

Guide to Mass Concrete,

American Concrete Institute (2010), ACI 301-10 Specifications for Structural Concrete,
Michigan
American Society of Testing and Materials (2010), ASTM C1074 - 10a Standard
Practice for Estimating Concrete Strength by the Maturity Method, Pennsylvania
American Society of Testing and Materials (2008), ASTM C618 - 08a Standard
Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in
Concrete, Pennsylvania
American Society of Testing and Materials, (2010), ASTM C494 / C494M - 10a
Standard Specification for Chemical Admixtures for Concrete, Pennsylvania
American Society of Testing and Materials (2008), ASTM C403 / C403M - 08 Standard
Test Method for Time of Setting of Concrete Mixtures by Penetration Resistance,
Pennsylvania
Bamforth, P.B., Mass Concrete , Concrete Society Digest No 2
Concrete Engineering Specialists (CES) Report to Shaw Group, 2010

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